Preparing and Storing a Free Flowing Frozen Supplementary Product

ABSTRACT

An apparatus for manufacturing cryogenically frozen supplementary beads, including a freezing chamber configured to contain a cryogenic liquid, at least one feed tray overlying the freezing chamber arranged and adapted to receive a liquid composition from a delivery source, the at least one feed tray having a plurality of orifices for the discharge of uniformly sized droplets of the liquid composition from the at least one feed tray, whereby the droplets are delivered by gravity into the freezing chamber there-below to form frozen beads, at least one clean-in-place structure, and a conveyor belt assembly comprising a conveyor belt, wherein at least a portion of the conveyor belt is positioned proximate a bottom of the freezing chamber such that the conveyor belt is positioned to receive frozen beads onto the conveyor belt.

This application is a divisional application claiming priority benefitto U.S. patent application Ser. No. 15/258,648, filed on Sep. 7, 2016.The entire contents and disclosures of the above application isincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to the field of frozensupplementary products and, more particularly, to a unique method ofpreparing a free-flowing frozen supplementary product, such asconfections, ice cream, yogurt, bacteria cultures, such as probiotics,pharmaceuticals, etc.

BACKGROUND OF THE INVENTION

Frozen ice cream and yogurt sales have grown dramatically over recentyears. This growth has been achieved primarily through extensiveadvertising and mass marketing efforts. In particular, dairycooperatives have been promoting ice cream and yogurt as health foods.In addition, a number of new and developing ice cream parlor franchiseshave conducted aggressive advertising campaigns in order to firmlyestablish themselves in the marketplace.

If the rising trend in sales is to continue in today's competitivemarketplace, however, it is clear that a more sophisticated product mustbe developed to attract discriminating consumers. A need is thereforeidentified for such a product.

SUMMARY OF THE INVENTION

Embodiments of the present invention relate to an apparatus formanufacturing cryogenically frozen supplementary beads, including afreezing chamber configured to contain a cryogenic liquid, at least onefeed tray overlying the freezing chamber arranged and adapted to receivea liquid composition from a delivery source, the at least one feed trayhaving a plurality of orifices for the discharge of uniformly sizeddroplets of the liquid composition from the at least one feed tray,whereby the droplets are delivered by gravity into the freezing chamberthere-below to form frozen beads, at least one clean-in-place structure,and a conveyor belt assembly comprising a conveyor belt, wherein atleast a portion of the conveyor belt is positioned proximate a bottom ofthe freezing chamber such that the conveyor belt is positioned toreceive frozen beads onto the conveyor belt.

Additional embodiments relate to an apparatus for manufacturingcryogenically frozen supplementary beads, including an elongated housingincluding an intake end and a discharge end including a chute, theelongated housing in the form of a channel from the intake end to thechute, wherein the intake end of the elongated housing includes anintake configured to extend to a bottom of a cryogenic chamber when theapparatus is positioned to receive the frozen bead from the cryogenicchamber, and a conveyor belt disposed within the channel of theelongated housing from the intake end to the discharge end.

Additional embodiments relate to a method of preparing and storing afree-flowing frozen supplementary product, including preparing asupplementary composition for freezing, dripping the supplementarycomposition into a freezing chamber, freezing the dripped supplementarycomposition into frozen beads, and transporting the frozen beads by aconveyor belt away from the freezing chamber, wherein transporting thefrozen beads includes receiving the frozen beads through an intake of anelongated housing, receiving the frozen beads onto a first portion ofthe conveyor belt within the elongated housing, and discharging thefrozen beads by dropping the frozen beads from the conveyor belt througha chute, and cleaning an apparatus used to prepare the free-flowingsupplementary product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a diagram cross-sectional view of an apparatus forpreparing the free-flowing, frozen supplementary product in accordancewith the principles of the present invention.

FIG. 2 depicts a diagram of a cross-sectional view of the apparatus ofFIG. 1 with greater detail of a conveyor belt of the apparatus inaccordance with the principles of the present invention.

FIG. 3 depicts a top-down view diagram of a mesh conveyor belt for usewith the apparatus of FIG. 2 in accordance with the principles of thepresent invention.

FIG. 4A depicts a cutaway side-view diagram of the conveyor belt of FIG.3 in accordance with the principles of the present invention.

FIG. 4B depicts a side-view diagram of the conveyor belt of FIG. 3 inaccordance with the principles of the present invention.

FIG. 5 depicts a diagram of a side view of an alternative conveyor beltfor use with the apparatus of FIG. 2 in accordance with the principlesof the present invention.

FIG. 6 depicts a side view of a conveyor belt assembly in accordancewith the principles of the present invention.

FIG. 7 depicts a view of the intake end of the conveyor belt assembly inaccordance with the principles of the present invention.

FIG. 8 illustrates another view of the intake end of the conveyor beltassembly in accordance with the principles of the present invention.

FIG. 9 depicts the apparatus of FIG. 1 comprising a self-cleaningextension.

FIG. 10 depicts a diagram of an example interaction of a roller and ahousing of the apparatus of FIG. 1 in accordance with the principles ofthe present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Previous methods and apparatuses for manufacturing cryogenically frozenbeads contain an auger to transport the beads from a cryogenic liquidrefrigerant in a bottom of a chamber to a shaker and from the shaker toa container for packaging. However, transportation of the beads by anauger grinds some of the beads against the outer wall of the surroundingtube. The ground beads may become smaller than desired for the endproduct, and therefore must be separated using a shaker beforepackaging. Thus, transporting the beads without grinding the beads maybe desirable, such that separating the beads using a shaker may nolonger be necessary.

“About,” as used in this application, means within plus or minus one atthe last reported digit. For example, about 1.00 means 1.00±0.01 unit.

“Around,” when used to describe a unit or percentage, means within plusor minus one unit or plus or minus one percentage point.

“Proximate,” when used to describe position of an element relative toone object of a set of multiple objects, conveys that the element ispositioned closer to the one object than any other object of the set.

“Substantially,” as used in this application with reference to an angle,means within one degree. For example, substantially planar means withinone degree counterclockwise and within one degree clockwise of planarorientation.

“Substantially,” as used in this application with reference to a shape,means within manufacturing tolerance of manufacturing the referencedshape as well as any other shape falling within the doctrine ofequivalents for the referenced shape.

“Substantially similar,” as used in this application, means having atleast each of the properties of the referenced structure plus theadditional structure disclosed. If the additional structure conflicts,the additional structure supersedes the structure incorporated byreference.

“Free-flowing,” as used herein, is a broad term which includes theability of the product to flow as individual beads, with lithe or noclumping or sticking to each other, during such pouring. There may beslight sticking after a period of storage, but a light tap on thecontainer may unstick the beads and allow them to be free-flowing. Thegenerally spherical shape helps contribute to the free-flowing, pourableproduct. It may be desired that the beaded product is in a free-flowingformat so that it is readily pourable.

“Supplementary,” as used in this application, means at least one ofalimentary, comestible, pharmaceutical, and probiotic.

“Sanitary roller,” as used in this application, means either a shieldedroller or an open roller. Shielded sanitary rollers may comprise amechanism to prevent and/or restrict the entry of fluid into the roller.For example, shielded sanitary rollers may comprise one or morereciprocating, rotary, or oscillating seals. Example seals include anO-ring, a double O-ring, an X-ring, a square-ring, and/or a U-cup.Furthermore, each seal may be situated in a corresponding groove suchthat the seal maintains contact with the roller and/or housing. Opensanitary rollers may comprise openings that allow fluid to pass throughthe roller. Open rollers may allow for easy cleaning by passing fluidthrough the roller.

For the purposes of this disclosure, “and” and “or” shall be construedas conjunctively or disjunctively, whichever provides the broadestdisclosure in each instance of use of “and” and “or.”

For the purposes of this disclosure, structures disclosed in singularform are not limited to a single structure, but can include multipleinstances of the disclosed structure, unless specifically statedotherwise.

The detailed description set forth below in connection with the appendeddrawings is intended as a description of various embodiments of theinvention and is not intended to represent the only embodiments in whichthe invention may be practiced. The detailed description includesspecific details for the purpose of providing a thorough understandingof the invention. However, it will be apparent to those skilled in theart that the invention may be practiced without these specific details.In some instances, well known structures and components are shown inblock diagram form in order to avoid obscuring the concepts of theinvention.

FIG. 1 depicts a diagram of a cross-sectional view of an apparatus 10for preparing the free-flowing, frozen supplementary product inaccordance with the principles of the present invention. It should berecognized that this apparatus 10 is merely being described as anexample of one type of apparatus designed for this purpose. Otherdesigns may, of course, be utilized in accordance with the presentmethod to produce the free-flowing, frozen supplementary product.

As shown, the apparatus 10 can include a freezing chamber 12 having aninner wall 14 and outer wall 16. In some embodiments, both the walls 14and 16 may be constructed of stainless steel to provide both strengthand corrosion resistance. However, the walls 14 and 16 may comprise anymaterial sufficient to withstand cryogenic temperatures while retainingthe structural integrity of the freezing chamber 12. A thick layer ofthermal insulating construction 18 may be provided between the walls 14,16 to improve the efficiency of the freezing chamber by reducing thethermal transfer through the walls 14, 16 between the interior of thechamber 12 and the ambient environment. In some embodiments, the thermalinsulating construction 18 may include an insulating material, such asfiberglass. Other embodiments include a thermal insulating construction18 comprising a vacuum between the walls 14, 16.

The chamber 12 may be chilled by the direct addition of refrigerant froma refrigerant source 20 through the delivery line 22. A number ofdifferent refrigerants can be utilized, including liquid nitrogen.Liquid nitrogen is readily available, relatively inexpensive andrelatively inert to food products. It is also sufficiently cold toprovide for relatively rapid freezing of the product. As such, it isparticularly adapted for utilization in the processing of free-flowing,supplementary products in accordance with the present invention.

The temperature of the freezing chamber as well as the level of liquidrefrigerant may be maintained within a specified range through theutilization of a temperature control means 24 such as a thermostat as isknown in the art. More specifically, the temperature control means 24may be connected to a thermocouple 26. The thermocouple 26 may bepositioned to extend into the freezing chamber 12 at a selected heightbetween, for example, 4 to 18 inches above the bottom of the chamber tosense the temperature within the chamber. Where, for example, liquidnitrogen is utilized as the refrigerant, the thermostat may be set tomaintain the temperature within the chamber 12 at a thermocouple 26between approximately −184° C. (−300° F.) to approximately −195° C.(−320° F.). The positioning of the thermocouple 26 some 4 to 18 inchesabove the bottom of the chamber 12 may provide the necessary reservoirof refrigerant to quick freeze the droplets of the supplementarycomposition. The ultra-low temperature of the refrigerant can limit theformation of ice crystals in the product as it is frozen.Advantageously, by reducing the overall size of the ice crystals beingformed, the resulting frozen product may have a richer, creamier textureand exhibit a better overall flavor.

For example, when the temperature within the chamber 12 at thethermocouple 26 rises above the set range of operation (i.e. −300° to−320° F.), this can be an indication that the level of liquidrefrigerant has fallen below the thermocouple. As a result of theoperation of the temperature control means 24, a valve 27 may then beopened to allow delivery of liquid nitrogen from the source 20 throughthe line 22 to the chamber 12. Once the liquid refrigerant level withinthe chamber 12 reaches and contacts the thermocouple 26, the desiredlevel of liquid refrigerant for freezing the composition is restored andthe valve 27 may be closed.

Of course, alternative temperature or level control systems may beutilized. For example, a number of thermocouples 26 may be positioned atvarious heights within the chamber 12. The thermocouple 26 at thedesired liquid refrigerant level to be maintained can then be selectedand utilized as described above. In another alternative, a liquidnitrogen level controller such as manufactured and marketed by MinnesotaValley Engineering, Inc. under the trademark CRYO-MED (Model LL-450) maybe utilized.

Vents 29 may be provided in the walls 14, 16 near the top of thefreezing chamber 12. These vents 29 may serve to release rising nitrogenvapor from the chamber 12 and may prevent any build-up in pressure inthe chamber or any excess lowering of temperature near the top such thatthe dropper system is frozen over time. This exhaust can be controlledmanually by venting through an exit pipe which may be controlled by adamper. Alternatively, the exhaust gas can be collected under vacuum bythe use of an exhaust fan. This cold vapor can be routed to other partsof the process where cold vapors can be utilized such as in storagespaces or with packaging machines.

The first step of a method of the present invention may be to prepare asupplementary composition for freezing. In some embodiments, thecomposition may be dairy based and can include such ingredients ascream, milk, butter and/or eggs. Additional ingredients could includesugar, fruit extracts or some other flavoring component, such as vanillaextract. However, embodiments include probiotic formulations,pharmaceutical formulations, non-dairy based formulations for formingfrozen confectionary beads, etc.

After preparing the composition comes the step of slowly dripping thecomposition into the freezing chamber 12. This may be accomplished in anumber of ways. For example, as shown in FIG. 1, the composition C maybe pumped from a supply container 30 into a dropper system including atray 32 positioned across the upper end of the freezing chamber 12. Morespecifically, the composition may be pumped by pump 31 through the tube33 so as to be delivered through an inlet 35 in the top of the tray thatcloses the tray to prevent any residual dirt or dust in the air fromfalling into the composition. The bottom of the tray 32 can include aseries of apertures 34 through which the composition drips into thefreezing chamber 12. The apertures may have a diameter of between about0.3175 cm (0.125 inches) and 0.794 cm (0.3125 inches) so as to providethe desired size droplets of composition for freezing into beads. Ofcourse, the size of the droplets and rate of flow may be determined notonly by the size of the holes, but the thickness of the composition andin some cases the thickness of the tray.

As the droplets D of composition fall downwardly in the freezingchamber, they contact cold nitrogen gas rapidly vaporizing from the poolof liquid nitrogen P at the bottom of the chamber 12. As a result of thetemperature within the range of −162° C. (−260° F.) to −195° C. (−320°F.) (for liquid N₂), rapid freezing of the droplets of compositionoccurs. The small beads B that are produced might contain onlyrelatively small ice crystals. The beads B may have a smooth, sphericalappearance.

A conveyor belt assembly 50 for collecting the beads B may extend intothe bottom of the chamber 12 at an intake end of an elongated housing36. The conveyor belt assembly 50 may comprise a conveyor belt 38 withinthe housing 36. Furthermore, the conveyor belt 38 may extend from theintake end of the housing 36 to a discharge end comprising a chute 40.As shown, the conveyor belt 38 may be positioned at a conveying angle102 ranging from approximately 55° to approximately 60° with respect tothe horizontal plane. As depicted, the conveyor belt 38 may besubstantially parallel to the housing 36. The horizontal plane refers tothe plane that is perpendicular to the lengthwise plane of the apparatus10. Furthermore, the horizontal plane may be parallel to the ground whenthe apparatus 10 is in upright position upon the ground. Embodiments ofthe present invention also include an angle of approximately 50° fromthe horizontal plan, and 45° from the horizontal plane. The conveyorbelt 38 can include transport structures (not illustrated in FIG. 1)that move the beads B against gravity out of the bottom of chamber 12through the chute 40.

As the conveyor belt 38 is rotated, the beads B may be drawn upwardly inthe direction of action arrow E on the conveyor belt 38 and/or transportstructures. Liquid refrigerant, however, may not necessarily bewithdrawn from the freezing chamber 12 as the liquid nitrogen may drainback to the pool P.

Conveyor belt 38 may be comprised of any material that is resilientwhile bending under cryogenic conditions. Example materials includerubber and linked metal constructions. In embodiments having linkedmetal constructions. Small holes between the metal links may be used tostrain the cryogenic liquid from the beads B back to chamber 12.

Once the beads B reach the top of the conveyor belt 38, they may bedeposited by means of a chute 40 onto a sieve 42. The sieve 42 may beconnected to a shaking apparatus 44 as is known in the art. This shakingapparatus 44 can vibrate the beads B on the sieve 42. Thus, sifting ofthe beads B may occur with the relatively large beads having a diameterof, for example, approximately 2 mm or larger remaining on the surfaceof the sieve while the smaller beads and fragmented portions of brokenbeads may fall through the sieve into the collecting pan 46. Thatmaterial collected in the pan 46 may be melted and reprocessed by mixingback in with the composition C that is added to the tray 32 as describedabove.

The appropriately-sized beads (e.g. diameter of greater than 2 mm) mayflow over the sieve to a discharge chute 48 where they may be depositedinto a container (not shown). This container may be maintained open forsubstantially 1-10 minutes in order to allow any residual nitrogenrefrigerant retained in or on the surface of the beads to vaporize.Then, the container may be sealed and placed in a freezer for storage.

In order to prevent the beads B from sticking together during storageand thereby maintain their free-flowing character, they can bemaintained at a relatively low temperature. More specifically, if thebeads B are to be stored for greater than a period of approximately 30hours, they should be stored in the refrigerator at a temperature of atleast as low as −28.9 C.° (−20° F.). More preferably, the beads arestored at a temperature between −1.1° C. (−30° F.) and −40° C. (−40°F.).

Alternatively, if the beads B are to be consumed within a 30-hour period(or shorter period of 10-12 hours for certain compositions), they can bestored in the freezer at a temperature of −28.9° C. (−20° F.) or above.However, the beads B can be brought to a temperature between about−23.3° C. (−10° F.) and −28.9° C. (−20° F.), with −26.1° C. (−15° F.)providing good results. Warmer temperatures may result in the beadssticking together and the product losing its unique free-flowingproperty, thus reducing its consumer appeal. When served at a coldertemperature, many individuals may find that the product is too cold tobe fully enjoyed.

FIG. 2 depicts a diagram of a cross-sectional view of the apparatus ofFIG. 1 with greater detail of a conveyor belt 38 of the apparatus 10 inaccordance with the principles of the present invention. For example,conveyor belt 38 may comprise a belt 207 frictionally fit around one ormore rollers, 205 a and 205 b. The rotation of either roller 205 a or205 b may drive the rotation of the belt 207. By way of example, 205 bmay be a drive roller and 205 a may be a support roller. Furthermore,the rotation of the belt 38 may drive beads B from the bottom of chamber12 to the chute 40. In some embodiments, a retaining wall 201 may bespaced a straining distance 203 from the outside of the belt 207. Thestraining distance 203 may be sized at less than 2 mm, such that frozenbeads 2 mm in diameter or larger are corralled onto the belt 207. Insome embodiments, the smaller beads are not carried by the belt 207 tochute 40. Furthermore, some embodiments of the conveyor belt 38 do notgrind the beads B into smaller beads, such as by preventing grinding thebeads B between an auger flight and the outer tubing 209 of housing 36.Thus, some embodiments implementing the conveyor belt do not necessarilyrequire a sieve 42 and shaker 44 for separating beads having greaterthan or equal to 2 mm diameter from those with a smaller diameter.

As can be seen, guide rails 211 may be provided along both sides of theconveyor belt to guide the transport of the frozen beads B to the chute40. Guide rails 211 may comprise any material of sufficient rigidity toguide the frozen beads B with a tolerance of cryogenic temperatures.Examples include composites, certain rubbers, certain polymers, metals,etc.

In addition, the conveyor belt 38, 207 may be configured at a conveyingangle 102. The conveying angle 102 may aid in transportation ofappropriately sized beads, draining cryogenic liquid, and/or removal ofinappropriately sized beads. For example, the conveying angle 102 may beapproximately 55° to approximately 60° degrees from horizontal.

FIG. 3 depicts a top-down view diagram of a mesh conveyor belt 300 foruse with the apparatus of FIG. 2 in accordance with the principles ofthe present invention. The mesh conveyor belt 300 may comprise metal,such as steel, plastics, composites, rubber, cloth, etc. As can be seenin FIG. 3, the conveyor belt 300 may comprise links 302. The links 302may comprise crossbars 310 connected by wing hinges 308. In fact,crossbars 310 may extend through respective holes of wing hinges 308.Crossbars 310 may be pivotally connected with the respective wing hinges308.

Furthermore, rods 312 may extend between two respective crossbars 310.Rods 312 may be in pivotal relationship with both respective crossbars310. The rods 312 may also be spaced apart by a rod gap 314. The rod gap314 may be sized to retain beads B on the conveyor belt 300 duringtransport. Furthermore, the rod gap 314 may allow fluids to passthrough. In some embodiments, rod gap 314 may allow inappropriatelysmall beads to pass through. Therefore, rod gap 314 may be less than 2mm between respective rods 312, such that appropriately-sized beads aretransported from chamber 12 to chute 40.

The diameter of each crossbar 310 may extend orthogonally from the outersurface of the conveyor belt 300. For example, rod gaps 314 may be atransport structure for pushing the beads as the surface of conveyorbelt 300 moves from chamber 12 to chute 40. The number, size, andsurface area population density of the rod gaps 314 on the conveyor belt300 may be selected to control the size and rate of transport of beadsB. Furthermore, the rotation speed of the conveyor belt 300 may bealtered to manipulate the uptake of beads B.

The mesh 307 of the conveyor belt 300 may comprise the area of theintersections of the rods 312 and the crossbars 310.

The guide rails 211 may be substantially parallel with the belt 300 andmay be positioned relative to the belt 300. For example, the guide rails211 may be positioned to retain the frozen beads B on the conveyor belt300. Thus, the guide rails 211 may be positioned slightly above theconveyor belt 300. Furthermore the guide rails 211 may be set apartslightly wider than the width of the conveyor belt 300. Therefore, aguide span 304 may describe the distance from an outer edge of theconveyor belt 300 to the nearest surface of the nearest guide rail 211.Because the guide rails 211 may be configured to retain beads B on theconveyor belt 300 as the beads B travel to the chute 40, the guide span304 may be sized such that beads B of a predetermined size may beretained on the conveyor belt 300. Thus, the guide span 304 may be 2 mmor less, in order to allow very small beads to fall off. In someembodiments, the guide span 304 may be 4 mm or less. Guide span 304 mayalso be negative when the wing hinges 308 are sized such thatappropriately-sized beads B may fall through the wing hinges 308.

In some embodiments, the guide rails may be positioned above the mesh307. Therefore, mesh guide span 305, describing the distance from theoutside of the mesh 207 to the outside of the respective guide rail 211may be less than 2 mm, or even negative when the guide rails 211 arepositioned within the outer bounds of the mesh 307.

The guide rails 211 may be attached to supports 306 that may be attachedto the inside surface of the surrounding housing 36. In additionalembodiments, the attachment of the guide rails 211 to the supports 306may be removable such as by pins, clips, or other attachment mechanism.This attachment mechanism of the supports 306 can include a permanentanchor rail that runs down the interior of the housing 36. The anchorrail may be parallel beside the side of the conveyor belt 300 and mayrun the length of the conveyor belt 300. The anchor rail may contain alengthwise female grove in which a male groove of the removable guiderail 211 may be inserted to position the guide rail 211 for operation ofguiding the beads B along the conveyor belt 300. Alternative embodimentsinclude a female anchor rail running a portion of the length of thehousing and attached to the supports 306 for receiving the guide rail211.

Rod gaps 314 may comprise recesses in the conveyor belt 300. In someembodiments, rod gaps 214 may comprise holes through the conveyor belt300 such that the beads B are strained from the cryogenic liquid.Furthermore, cleaning fluids may pass through rod gaps 214.

FIG. 4A depicts a cutaway side-view diagram of the conveyor belt 300 ofFIG. 3 in accordance with the principles of the present invention.Retaining wall 401 may be similar in all respects to retaining wall 201.Furthermore, retaining wall 401 may be spaced similarly to retainingwall 201. Thus, straining distance 403 may be similar to strainingdistance 203. In addition, gap 407 may be a distance between the top ofrespective crossbars 310, as they pass under retaining wall. Gap 407 maybe sized to allow fluid to pass through. Furthermore, gap 407 may allowvery small beads to pass through.

Selection of the beads B may occur by the size and shape of the rod gaps314. For example, beads B having a diameter of about 10.0 mm or largermay be selected by rod gaps 314 sized 10.0 mm or larger. Additionally,beads B having a diameter of about 4.0 mm or larger may be selected byrod gaps 314 of 4.0 mm or less. Furthermore, beads B having a diameterof about 2.0 mm or larger may be selected by rod gaps 314 of 2.0 mm.Smaller diameter beads B may pass through rod gaps 314 larger than thediameter of the smaller diameter beads.

Link span 409 may represent the distance between respective crossbars310. Link span 409 may be sized to regulate the uptake density of beadsB. For example, an oversized link span 409 may not maximize uptakedensity due to beads B crowding and falling over the lower crossbar 310.However, an undersized link span 409 may reduce the transporting surfacearea of the mesh 307 by including unnecessary crossbars 310 (ifcrossbars 310 are configured such that beads B don't rest directly onthe crossbars 301, thereby reducing available surface area of theconveyor belt 300 for transport). Link span 409 may be predeterminedaccording to the diameter of crossbars 310.

Crossbars 310 may extend orthogonally from the surface of belt 300 at acrossbar height 411. The crossbar height may be predetermined to allowfor pushing the beads B as the conveyor belt 300 moves. For example,crossbar height 411 may be larger than the diameter of the correspondingbeads B. However, crossbar height 411 may be as small as one eighth ofthe diameter of corresponding beads B, depending on the conveyor beltangle 102. Using a smaller crossbar height 411 may increase transportsurface area of the conveyor belt 300.

Based on the configuration of the conveyor belt mesh 307, the rod gaps314, the straining distance 403, the gap 407, the retaining wall 401,and/or the crossbar height 411, beads B of a predetermined size may besifted from the frozen beads B. For example, beads of a 2.0 mm diametermay be sifted. In some embodiments, beads having a diameter of about 2.0mm to 10.0 mm may be sifted from the remaining beads.

FIG. 4B depicts a side-view diagram of the conveyor belt 300 of FIG. 3in accordance with the principles of the present invention.Specifically, the interaction of three links 302 is depicted. Respectivecrossbars 310 extend through each respective wing hinge 308.Furthermore, wing hinges 308 may extend orthogonally from the surface ofthe conveyor belt 300 at a guide height 405. This guide height 405 maybe sufficient to retain appropriately-sized beads B on the conveyor beltmesh 307. For example, guide height 405 may be at least one-eighth ofthe diameter of the corresponding beads B. Guide height 408 may belarger than the diameter of the corresponding beads B.

FIG. 5 depicts a diagram of a side view of an alternative conveyor belt500 for use with the apparatus 10 of FIG. 2 in accordance with theprinciples of the present invention. Conveyor belt 500 may comprisetransport structures, such as cleats 505. Cleats 505 may aid the rods312 and crossbars 310 in transporting the beads B on the conveyor belt500. Therefore, cleats 500 may be any transport structure fortransporting beads B from chamber 12 to chute 40. For example, cleats505 may span the width of the conveyor belt 500. Cleats 505 may extendorthogonally from crossbars 301 or from rods 312. Cleats 505 may span awidth of the conveyor belt 500 and may extend orthogonally from an outersurface of the conveyor belt 500. Furthermore, the cleats 505 may be setapart along the conveyor belt 500 at a predetermined spacing 511. Thecleats 505 may have a height 509, and a thickness 507. The height 509and spacing 511, in conjunction with the belt speed, may be correlatedwith the rate of formation of the beads B or the desired transportationrate of the beads B. In some embodiments, selection of the beads B mayoccur by the size of the cleats 505 in conjunction with the size ofspacing 511.

Furthermore, retaining wall 501 may be placed such that the beads B areguided by the operation of gravity onto the conveyor belt 500 andbetween the cleats 505. Retaining wall 501 may be positioned within aretention distance 503 of the tops of the respective cleats 505 when thecleats 505 pass under retaining wall 501. The retention distance may beless than the diameter of the smallest beads that are desired (e.g. lessthan 2 mm diameter).

In some embodiments, the cleats 505 may be constructed of solidmaterials that are resilient under cryogenic conditions, such as rubber,metals, and/or composites. However, other embodiments of the cleats 505include mesh constructions, such that the cleats 505 strain the beads Bfrom the cryogenic liquid. The cleats 505 may extend orthogonally fromthe conveyor belt 500 and between the guide rails 211 such that thebeads B on the conveyor belt 500 are confined to the space between twocleats 500 and the two guide rails 211.

Based on the configuration of the conveyor belt mesh of conveyor belt500, the corresponding rod gaps, the retention distance 503, theretaining wall 501, and/or the configuration of the cleats 505, such ascleat height 509, beads B of a predetermined size may be sifted from thefrozen beads B. For example, beads of a 2.0 mm diameter may be sifted.In some embodiments, beads having a diameter of about 2.0 mm to 10.0 mmmay be sifted from the remaining beads.

FIG. 6 depicts a side view of a conveyor belt assembly 600 in accordancewith the principles of the present invention. In some embodiments, theconveyor belt assembly 600 may be substantially similar to the conveyorbelt assembly 50.

Conveyor belt assembly 600 may comprise a motor 602 that is in rotatablecommunication with roller 205 b, such as via a rotary assembly 612.Thus, roller 205 b may be rotatably driven by motor 602. For example,motor 602 may cause rotation of belt 604 about roller 205 b. Roller 205b may share common axle 608 with motor 602. Thus, rotation of belt 38may drive rotation of support rollers 205, such as roller 205 a. Roller205 b and support rollers 205, 205 a may be rotatably connected viafrictional fit with belt 38. Support rollers 205 may be substantiallysimilar to support roller 205 a.

Furthermore, conveyor belt assembly 600 may comprise intake 616. Intake616 may receive the beads B such that belt 38 may transport the beads tochute 40. The intake 616 may receive material, such as frozen beads B,which may be fed from the chamber 12 to intake 616 by the operation ofgravity.

Conveyor belt assembly 600 may further comprise bell hub 604. Bell hub604 may comprise a connector for receiving cleaning fluids, such aswater, detergent, and/or disinfectant. Thus, conveyor belt assembly 600may be a clean-in-place assembly. A “clean-in-place assembly” and a“clean-in-place configuration” mean that the conveyor belt assembly 600can be cleaned by pumping cleaning fluids, such as water, soap,detergents, disinfectants, etc., through the clean-in-place conveyorbelt assembly 600 without removing the conveyor belt assembly 600 fromthe apparatus 10. Furthermore, cleaning fluids may clean each of thestructures within the housing 636. As the assembly 600 is cleaned,fluids may flow to the intake end 618. The fluids may be released fromthe intake end 618 via a drain line (explained with respect to FIG. 7).

FIG. 7 depicts a view of the intake end 618 of the conveyor beltassembly 600 in accordance with the principles of the present invention.By way of illustration, an axle 706 is depicted at a vertical anglerelative to a drain 708 rather than the alternative horizontal angledepicted in FIG. 6. Thus, axle 706 may rotatably engage roller 205 asuch that belt 38 is turned when axle 706 is turned.

Intake end 618 may be joined to cover 712. For example, intake end 618and cover 712 may be frictionally fit, joined with a bolt 704, etc. Forexample, cover 712 may comprise dome 702, such that incorrectly sizedparticles and/or other debris may be contained. Thus, drain line 708 maybe used to remove the incorrectly sized particles, debris, cleaningfluids, and/or other waste. For example, cap 710 may be place over drainline 708 such that any contained liquid nitrogen, beads, etc. does notdrain during operation. However, operation may be temporarily ceased forcleaning. Drain line 708 may be connected to a hose for rinsing intakeend 618 with water, soap, rinse solutions, and/or disinfectants.Alternatively, water, soap, rinse solutions, and/or disinfectants may bepassed into the conveyor belt assembly 600 through the chute 40 and/orbell hub 604.

While the conveyor belt assembly 600 is in operation conveying material,the drain line 708 may remain closed, for example by securely butremovably attaching the drain cap 710 to the drain line 708. In oneembodiment, the drain cap 710 may be removably attached to the drainline 708 with sanitary Tri-Clamp fittings. For example, Tri-Clampferrule P/N L14AM7 may be used for the drain line 708. In thisembodiment, the drain cap 710 is Tri-Clamp solid end cap P/N 16AMP. ATri-Clamp gasket P/N 40MP-UW is inserted between the drain line 708 andthe drain cap 710, and Tri-Clamp single pin heavy duty clamp P/N 13MHHMremovably secures the drain cap 710 to the drain 708.

FIG. 8 illustrates another view of the intake end 618 of the conveyorbelt assembly 600. This embodiment includes a sanitary roller 205 a thatcomprises a solid material. In some embodiments, all the rollers 205,205 a, and 205 b comprise sanitary rollers. Sanitary roller 205 a mayextend from one side of the housing 636 to the opposite side. The axleis not depicted and is further explained with respect to FIG. 10.Sanitary roller 205 a may be protected by one or more O-rings 801 at theintersection of the housing 636 and the roller 205 a. Furthermore,support rollers 205 may comprise sanitary support rollers 205 a.

Debris could fall from material conveyed by the conveyor belt assembly600, accumulating around the axle 706 and roller 205 a. Therefore, someembodiments include solid construction of the roller 205 a and the axle706 comprising composite materials, such as Teflon. Furthermore, gaskets801 may be situated on the axles 706 and on both sides of the rollers205, 205 a, 205 b. The gaskets 801 may seal the bearings, or otherrotation mechanism, of the rollers 205, 205 a, 205 b such that debris isprevented from entering the bearings. Example gaskets include O-rings orother gaskets and may comprise composites, Teflon, rubber, silicone,metal, etc. For example, Teflon axles 706 with an O-ring gasketpositioned on the outside of the rollers, such as rollers 205 a, 205 b,the unmarked support rollers, and any undepicted rollers, may keep therollers clean, operable, and easy-to-clean.

In some embodiments, the conveyor belt assembly 600 may be readilycleaned without dismantling. To clean the conveyor belt assembly, thedrain line 710 may be opened, and wash and rinse solutions anddisinfectants may be passed into the housing 636 through the chute 40and/or the intake 616. Alternatively, a nozzle may be provided at theoutlet end of the conveyor belt assembly 600 for accepting wash andrinse solutions. The wash and rinse solutions and disinfectants may flowdownward against the belt 38 and rollers 205, 205 a, 205 b, passingfreely between the axle 706 of the roller 205 b, and exiting from thedrain line 708. The currents or fluid flow forces created by thecleaners and disinfectants may effectively remove debris from the intakeend 618, allowing the conveyor belt assembly 600 to be cleaned withoutdismantling. When removal of the cover 712 is required to allowinspection of the interior of the intake end 618, the axle 706 can beadvantageously attached to the housing 636, allowing removal of thecover 712 without destabilizing the conveyor belt 38.

FIG. 9 depicts the apparatus 10 of FIG. 1 comprising a cleaningextension 905. As can be seen, the cleaning extension 905 may extendinto chamber 12 of apparatus 10. Thus, apparatus 10 may comprise aclean-in-place configuration, wherein cleaning fluids can be pumpedthrough apparatus 10 without disassembly of apparatus 10. Cleaningextension 905 may comprise one or more spray balls 903 a and 903 b.Additionally, each spray ball 903 a and 903 b may comprise respectivesets of holes 909. Each respective hole 909 may be in fluidcommunication with intake 901 through the cleaning extension 905. Inthis manner, cleaning solution comprising may be pumped into thecleaning extension 905, through the respective holes 909 of the sprayballs 903 a and 903 b in order to clean the interior of apparatus 10. Insome embodiments, the cleaning solution may comprise water. In addition,the cleaning solutions may comprise one or more detergents.

In some embodiments, a first spray ball 903 a may be positioned over thedrip tray 32 such that water and/or detergents may be sprayed onto driptray 32 and through apertures 34 during cleaning. Top 907 may enclosespray ball 903 a such that water and/or detergent are contained whensprayed from the spray ball 903 a. Additionally, a second spray ball 903b may extend into chamber 12. In these embodiments, water and/ordetergents may be sprayed onto the underside of the drip tray 32 as wellas the walls 14 of the chamber 12. Of course, the interior (e.g. thechamber 12) of the apparatus may be warmed above cryogenic temperaturesfor cleaning.

Although inlet 35 may be repositioned, inlet 35 may allow thecomposition to enter the apparatus 10 to be dripped through tray 32.Therefore, cleaning extension 905 may clean composition out of theapparatus 10. For example, routine cleanings and/or cleanings betweenflavoring changes may be performed.

FIG. 10 depicts a diagram of a partially exploded diagram of an exampleinteraction of a roller and a housing of the apparatus of FIG. 1 inaccordance with the principles of the present invention. An o-ringrecess 1003 may be formed in the interior of the housing 36 such thato-ring 1001 may fit inside. In some embodiments, this fit preventsfluids from entering the o-ring recess and prevents fluid from reachingthe axle 706. In some embodiments, the axle 706 may be a smallerdiameter than the roller 205 a such that the axle 706 fits within o-ring1001. Thus, a side of roller 205 a may be frictionally fit against theo-ring 1001 such that the axle 706 is protected.

The foregoing description has been presented for purposes ofillustration and description. It is not intended to be exhaustive or tolimit the invention to the precise form disclosed. Obvious modificationsor variations are possible in light of the above teachings. Theembodiment was chosen and described to provide the best illustration ofthe invention and its practical application to thereby enable one ofordinary skill in the art to utilize the invention in variousembodiments and with various modifications as are suited to theparticular use contemplated. All such modifications and variations arewithin the scope of the invention as determined by the appended claimswhen interpreted in accordance with the breadth to which they arefairly, legally and equitably entitled.

In summary, numerous benefits have been described which result fromemploying the concepts of the present invention. In particular, a methodof the present invention allows the preparation, storing and serving ofa unique, free-flowing, frozen supplementary product. Because theproduct is quick frozen, it can be smoother and creamier and provide afull-bodied flavor. Advantageously, the resulting product may have acertain sophistication that appeals to today's discriminating consumerswho want something special.

The previous description is provided to enable any person skilled in theart to practice the various embodiments described herein. Variousmodifications to these embodiments will be readily apparent to thoseskilled in the art, and the generic principles defined herein may beapplied to other embodiments. Thus, the claims are not intended to belimited to the embodiments shown herein, but are to be accorded the fullscope consistent with each claim's language, wherein reference to anelement in the singular is not intended to mean “one and only one”unless specifically so stated, but rather “one or more.” All structuraland functional equivalents to the elements of the various embodimentsdescribed throughout this disclosure that are known or later come to beknown to those of ordinary skill in the art are expressly incorporatedherein by reference and are intended to be encompassed by the claims.Moreover, nothing disclosed herein is intended to be dedicated to thepublic regardless of whether such disclosure is explicitly recited inthe claims. No claim element is to be construed under the provisions of35 U.S.C. § 112, sixth paragraph, unless the element is expresslyrecited using the phrase “means for” or, in the case of a method claim,the element is recited using the phrase “step for.

What is claimed is:
 1. An apparatus for manufacturing cryogenicallyfrozen supplementary beads, comprising: a freezing chamber configured tocontain a cryogenic liquid; at least one feed tray overlying thefreezing chamber arranged and adapted to receive a liquid compositionfrom a delivery source, the at least one feed tray having a plurality oforifices for the discharge of uniformly sized droplets of the liquidcomposition from the at least one feed tray, whereby the droplets aredelivered by gravity into the freezing chamber there-below to formfrozen beads; at least one clean-in-place structure; and a conveyor beltassembly comprising a conveyor belt, wherein at least a portion of theconveyor belt is positioned proximate a bottom of the freezing chambersuch that the conveyor belt is positioned to receive frozen beads ontothe conveyor belt.
 2. The apparatus of claim 1, wherein the at least oneclean-in-place structure comprises: an upper spray ball positioned tospray cleaning solution onto the at least one feed tray.
 3. Theapparatus of claim 1, wherein the at least one clean-in-place structurecomprises: a lower spray ball positioned to spray cleaning solution ontoan interior wall of the freezing chamber.
 4. The apparatus of claim 1,further comprising: an elongated housing comprising an intake end and adischarge end comprising a chute, wherein the elongated housing isformed around the conveyor belt from the intake end to the chute.
 5. Theapparatus of claim 4, wherein the at least one clean-in-place structurecomprises the conveyor belt looped around and frictionally engaged withat least one sanitary roller.
 6. The apparatus of claim 4, wherein theat least one clean-in-place structure comprises a drain line at theintake end of the housing.
 7. The apparatus of claim 4, wherein the atleast one clean-in-place structure comprises a cleaning intake at thedischarge end.
 8. An apparatus for manufacturing cryogenically frozensupplementary beads, comprising: an elongated housing comprising anintake end and a discharge end comprising a chute, the elongated housingin the form of a channel from the intake end to the chute, wherein theintake end of the elongated housing comprises an intake configured toextend to a bottom of a cryogenic chamber when the apparatus ispositioned to receive the frozen bead from the cryogenic chamber; and aconveyor belt disposed within the channel of the elongated housing fromthe intake end to the discharge end.
 9. The apparatus of claim 8,wherein the conveyor belt is looped around and frictionally engaged withat least one sanitary roller.
 10. The apparatus of claim 8, wherein theelongated housing comprises a drain line at the intake end of thehousing.
 11. The apparatus of claim 8, wherein the elongated housingcomprises a cleaning intake at the discharge end.
 12. The apparatus ofclaim 8, further comprising: a drive motor assembly in rotarycommunication with the conveyor belt, the drive motor assemblyconfigured to rotate the conveyor belt toward the discharge end.
 13. Theapparatus of claim 8, wherein the conveyor belt is disposed at aconveying angle relative to a plane that is perpendicular to across-sectional plane of the intake.
 14. The apparatus of claim 13,wherein the conveying angle is about 50 degrees to about 60 degreesrelative to the plane.
 15. A method of preparing and storing afree-flowing frozen supplementary product, comprising: preparing asupplementary composition for freezing; dripping the supplementarycomposition into a freezing chamber; freezing the dripped supplementarycomposition into frozen beads; and transporting the frozen beads by aconveyor belt away from the freezing chamber, wherein transporting thefrozen beads comprises: receiving the frozen beads through an intake ofan elongated housing, receiving the frozen beads onto a first portion ofthe conveyor belt within the elongated housing, and discharging thefrozen beads by dropping the frozen beads from the conveyor belt througha chute; and cleaning an apparatus used to prepare the free-flowingsupplementary product.
 16. The method of claim 15, wherein cleaningcomprises: running water into the elongated housing through a receiverpositioned proximate the discharge end of the elongated housing.
 17. Themethod of claim 15, wherein cleaning comprises: draining water out ofthe elongated housing through a drain line positioned proximate theintake end of the elongated housing.
 18. The method of claim 15, whereincleaning comprises: spraying water from an upper spay ball positioned tospray the at least one feed tray.
 19. The method of claim 15, whereincleaning comprises: spraying water from a lower spray ball positioned tospray an interior wall of the freezing chamber.